Kawasaki KLX 300 R 1993-1997 Workshop Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 84795

Mots clés: 1993 1994 1995 1996 1997 Kawasaki KLX 300 R KLX Series Motorcycle Motorcycles

Variantes de produits

Description

The Kawasaki KLX300R is a distinguished off-road motorcycle, produced between 1993 and 1997. Engineered for demanding terrain, this model embodies Kawasaki's heritage of building robust and capable dual-sport and off-road machines. Its design emphasizes performance and reliability, making it a favored choice for enthusiasts and competition riders seeking a dependable partner for challenging adventures. This Workshop Service Manual (WSM) provides comprehensive guidance for the maintenance and repair of the Kawasaki KLX300R. It covers all essential systems, including detailed procedures for engine and transmission overhauls, chassis and suspension adjustments, and electrical system diagnostics. The manual is designed to empower mechanical technicians and knowledgeable owners with the dealership-level information necessary to perform any repair, ensuring optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX300R

Model Variant:

Off-Road/Competition

Product Type:

Workshop Service Manual

Codes

Applicable Years:

1993, 1994, 1995, 1996, 1997

👋 Introduction

Market Position

Target Audience:

Mechanical technicians and knowledgeable owners/enthusiasts of the Kawasaki KLX300R

Competitive Analysis

Value Proposition:

Provides comprehensive, dealership-level service information, enabling DIY maintenance and repair to save costs and ensure quality work

Key Features

Completeness:

Contains all necessary instructions for any repair the KLX300R may require, mirroring authorized dealer service department resources

Reliability:

Offers the most reliable information, verified for accuracy

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair and overhaul for the Kawasaki KLX300R

Page Count

Page Count:

Not specified, typical for workshop manuals is 500+ pages

Manual Type

Manual Type:

Workshop Service Manual (WSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly and assembly, tuning, lubrication, cooling (if applicable), fuel system, ignition system, exhaust system

Transmission Systems:

Transmission disassembly and assembly, clutch operation, gear shifting mechanisms

Chassis Systems:

Frame, suspension (front fork, rear shock), wheels, tires, braking system (front and rear), steering system

Electrical Systems:

Wiring diagrams, lighting, ignition, charging system, starter system, electrical component testing and repair

Bodywork And Fittings:

Body panel removal and installation, seat, fenders, handlebars, footpegs

Procedures Included

Maintenance Procedures:

Routine maintenance, tune-ups, fluid changes, filter replacement, lubrication, brake adjustments, chain adjustment

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, component testing methods

Repair Procedures:

Detailed step-by-step instructions for overhauling and repairing all major components and systems

Disassembly And Assembly:

Complete instructions for taking apart and putting back together all mechanical and electrical assemblies

Technical Depth

Depth Of Information:

Advanced diagnostics, complete engine and transmission rebuilds, electrical system troubleshooting, component-specific overhauls

Proprietary Components:

Includes instructions for proprietary components and references manufacturer guidelines where applicable

Special Emphasis

Safety Warnings:

Highlights critical safety information using 'WARNING', 'CAUTION', and 'NOTE' symbols

Special Tools:

Identifies and illustrates Kawasaki special tools required for specific adjustments and repairs

📊 Manual Specifications

File Format

File Format:

Print Quality

Printability:

Yes, printable pages

Binding Type

Binding Type:

Digital (PDF download, not a physical copy)

Paper Type

Paper Type:

N/A (Digital format)

Delivery

Delivery Method:

Fast and Free Electronic Delivery via Email

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, DOHC, 4 valves

Displacement:

292 cc (17.8 cu in)

Bore X Stroke:

78.0 x 61.2 mm (3.07 x 2.41 in)

Cooling System:

Liquid-cooled

Performance

Horsepower:

Estimated 30-35 HP (Actual figures may vary based on tune and specific year)

Torque:

Estimated 18-20 lb-ft (Actual figures may vary based on tune and specific year)

Fuel System

Carburetion:

Keihin CVK32 carburetor (common for this era, specific model may vary)

Ignition

Ignition System:

Digital CDI

Lubrication System

Lubrication Type:

Wet sump with remote oil cooler (standard on R models)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmission:

N/A (Typically single transmission option for competition models)

Features

Clutch Type:

Wet, multi-disc

📐 Dimensions

Exterior

Length:

Approx. 2170 mm (85.4 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1190 mm (46.9 in)

Weights

Dry Weight:

Approx. 116 kg (255.7 lbs)

Wet Weight:

Approx. 122 kg (269 lbs) (with all fluids)

Wheelbase

Wheelbase:

Approx. 1435 mm (56.5 in)

Ground Clearance

Ground Clearance:

Approx. 310 mm (12.2 in)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable for off-road competition vehicles in standard automotive safety ratings

Active Features

Active Safety:

Disc brakes (front and rear) for effective stopping power

Passive Features

Passive Safety:

Sturdy frame construction, ergonomic rider controls

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic off-road motorcycle with minimal electronic features)

Driver Assistance

Driver Assistance Features:

N/A (Designed for off-road performance, not equipped with electronic rider aids)

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific intervals, typically every 1000-1500 miles or 6-12 months

Air Filter Cleaning:

Frequent cleaning/replacement recommended, especially after off-road use

Spark Plug Replacement:

Refer to manual for specific mileage, typically every 3000-6000 miles

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-40 recommended (verify with manual for specific viscosity based on temperature)

Engine Oil Capacity:

Approx. 1.7 L (1.8 US qt) (with filter change)

Coolant Type:

High-quality antifreeze coolant (ethylene glycol based) mixed with distilled water (50/50 ratio)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Wear Items:

Clutch wear, chain and sprockets, wheel bearings, fork seals, exhaust system (rust/corrosion)

Carburetor Tuning:

May require periodic cleaning and adjustment due to fuel quality variations or off-road usage

Electrical Connections:

Corrosion or looseness in electrical connectors can occur with age and exposure to elements

Technical Tips

Torque Wrench Importance:

Emphasized use of a torque wrench for critical fasteners to ensure proper assembly and prevent component damage

📚 Vehicle History

Brand Heritage

Kawasaki Heritage:

Kawasaki has a long-standing reputation for producing durable and high-performance off-road motorcycles.

Model Evolution

Klx300R Evolution:

The KLX300R was a key model in Kawasaki's dual-sport and off-road lineup during the 1990s, known for its off-road capability and usability.

Production

Production Period:

1993-1997 for this specific generation of the KLX300R

Manufacturing Location:

Japan (typical for Kawasaki motorcycles of this era)

🏆 Awards & Recognition

Recognitions

Awards And Recognitions:

While specific awards for this model generation are not widely documented, the KLX series is generally well-regarded for its off-road prowess and reliability.